Electrocoating composition of a polyamine self-condensed epoxy adduct and coatings produced thereby

ABSTRACT

The invention relates to a novel electrocoating composition for metallic substrates that exhibits &#34;thick-build&#34; protective properties at &#34;medium-build&#34; thicknesses. It is composed of a self-addition epoxy resin-polyamine adduct, a blocked isocyanate cross-linker, a polyglycol-polyamine grind resin, a plasticizer, an anti-cratering agent and pigments.

Since their development in the 1960's, cationic electrodeposition resinshave been widely applied as coatings for metal substrates. Mostautomobile manufacturers look to these coatings as primary protectiveagents against harmful effects of the environment. Desirable automobilecoating properties, such as corrosion resistance, flexibility andsubstrate adherence, occur in part because of the presence of suchcationic resins.

In a typical electrocoating, the complete composition includes theprincipal (cationic) resin, a cross-linker, a grind resin, pigments, andother additives such as control agents, solvents and fillers. Mostprincipal resins applied in this context typically constitute adducts offlexibilized epoxy resins (combinations of aromatic diepoxides anddifunctional flexibilizing agents, such as aliphatic diols) andterminating polyamines. The cross-linkers are typically blockedpolyisocyanates. The grind resins are typically lower weight versions ofthe principal resin or are surfactant-like compounds with activehydrogen groups that can react with the cross-linker. It is generallythought that the aromatic moieties of the resins in the coatingpartially contribute to hardness and corrosion resistance while thealiphatic portions contribute to its flexibility.

The thicknesses of coatings also affect many of their protectiveproperties. Corrosion resistance, chip resistance, color, finish depth,and other, similar factors are in part dependent upon this physicalparameter.

Generally, electrocoatings will fall into one of three thickness or"build" categories. Standard-build coatings will range in thickness from15 to 22 microns; medium-build coatings will range in thickness from 24to 28 microns; and thick-build coatings will range in thickness from 30to 40 microns. Of these three, the thick-build coatings best withstandthe rigors of environmental challenge.

Nevertheless, thick-build coatings have several drawbacks. The first istheir more costly nature owing to the higher resin and pigment content.The second is their tendency to produce a rough finish. Third is theirgreater flow and throw power variability as they are beingelectro-deposited.

Recent developments in the chemistry of cationic resins havesignificantly reduced cost factors for production of all thesecategories of coatings. For example, in U.S. Pat. Nos. 4,661,541 and4,780,524, adducts of polyamines and a self-addition epoxy resin aredescribed. These principal resins are fully as flexible as the chainextended resins employing diols, but they lack the diol moiety. Theirflexibility is introduced by the multiple self-condensation of the epoxygroups of the starting epoxy resin component. This self-condensation iscontrolled so that undesirable gellation and high polymer chainbranching are minimized.

These self-addition resins follow the pattern of physical propertiesknown for cationic resins. Chemical factors being equal, the protectiveproperties of the resulting coatings are directly related to theirthicknesses. Consequently, the drawbacks attendant with a thick-buildcoating produced from such self-addition resins also result.

It is an object, therefore, to develop a coating composition fromself-addition epoxy resins that exhibits desirable protectiveproperties. It is a further object to develop such a coating in a costeffective manner. Yet another object is the development of a coatingthat contains a self-addition principal resin and that exhibitsthick-build protective properties at a medium-build thickness.

SUMMARY OF THE INVENTION

These and other objects are achieved by the present invention which isdirected to a coating composition of a self-addition epoxyresin-polyamine adduct. The novel compositions contain non-gelled,self-addition principal resins and have highly desirable protectiveproperties.

The composition according to the invention is composed of a principalresin, a cross-linker, a grind resin, pigments, a plasticizing resinand, optionally, an anti-crater resin. The principal resin is aself-addition epoxy resin-polyamine epoxy adduct having pendantalkylphenoxy groups. The cross-linker is a blocked polyisocyanatecompound, preferably a toluene diisocyanate compound, a blockedisocyanurate of hexane diisocyanate or mixtures thereof. The grind resinis a reaction product of an aromatic diglycidyl ether, an aromatic diol,an aminopolyalkoxy alcohol, diamines and an alkylaryl glycidyl ether.The plasticizer is preferably an poly(alkylene oxide) alcohol compound,most preferably aryl-substituted. The anti-cratering agent is selectedfrom polyacrylates, polyethers, polyesters, and silicones. One preferredmaterial is a polyacrylate resin having pendant alkyl, aromatic anddialkylamino groups. The pigments are selected from inorganic,organometallic and organic compounds contributing color, bulk, fillerand catalytically reactive properties to the composition.

In general, the weight percentages of components present in thecomposition relative to the total weight of non-volatile solids areabout 30% to 55% principal resin, about 15% to 30% cross-linker, up toabout 20% grind resin, about 3% to 12% plasticizer, up to about 35%pigments and up to about 3% anti-cratering agent. Adjustments of theseranges can be made according to the specific needs of the coatingapplication at hand, but the adjustment will require rebalancing othersimilar components present in the composition. Throughout thisspecification and appended claims, the phrase "up to about" is intendedto recite compositional ranges which include 0% at the lower end.

The composition can also be formulated into an electrodeposition bathaccording to the invention. Defoamer, neutralizing acids, solvents andaqueous media are further ingredients present in such a bath. In atypical bath formulation, the pH will range from between 4.5 and 7.

Further included according to the invention are metallic articleselectrocoated with the foregoing composition.

DETAILED DESCRIPTION OF THE INVENTION

The composition of the invention is a fully formulated, cationicelectrodeposition coating that has application for all metallicsubstrates. Without significant pilot or field tests, it can replace thecationic electrocoating formulations presently applied in commercialoperations and will exhibit superior protective properties and costsavings. Little or minimal adjustments of its electrocoating parametersare required relative to those accorded to the formulations sold on themarket.

Its advantages over commercial formulations include better corrosionresistance, better flexibility, a simpler, more foolproof design, andcost savings through development of thick-build properties at amedium-build thickness.

Although not intended as a characterization of the invention, it isbelieved that the combination of the self-addition principal resin, thecross-linker, the grind resin and the plasticizer develop the protectiveproperties discovered according to the present composition. As a coatingon an article, these ingredients are merged into a three-dimensionalmatrix supporting the pigment. Their individual chemical structures, ofcourse, are fused into the matrix, and all components are in somefashion cross-linked together so that the composite properties of thecoating are more than the properties of the individual ingredients. Whatresults is a coating with thick-build properties at a medium-buildthickness.

The principal resin generally is characterized in U.S. Pat. Nos.4,661,541 and 4,780,524, the disclosures of which are incorporatedherein by reference. It constitutes a self-addition aromatic oralkylaromatic diepoxide adducted with a mixture of amines. Theself-addition aromatic or alkylaromatic diepoxide is a reaction productof an aromatic or alkylaromatic diepoxide precursor of molecular weightof from about 800 to 1500 and an alkylphenol of the formula RC₆ H₄ OH,wherein R is hydrogen or an alkyl group of from 1 to 18 carbons. Themolar ratio of diepoxide precursor to alkylphenol ranges fromapproximately 4:1 to 1.5:1, preferably about 2:1. The primary productformed is a self-addition dimer of the diepoxide precursor with apendent alkylphenoxy group. Trimers, tetramers, pentamers and hexamersand the like of the diepoxide precursor, each having one or more pendentalkyl phenoxy groups, are also formed. The actual self-addition productcontains a Gaussian distribution of such oligomers which is centeredupon the dimers through tetramers.

In the principal resin, the amine mixture adducted to the self-additiondiepoxide produces terminal amine groups. These provide the cationicsites which largely contribute to the ready dispersibility of theprincipal resin in the aqueous acidic medium. The equivalent ratio ofamine mixture per epoxide group of the self-addition diepoxide is from0.75 to 1, primary and secondary amines being counted as one equivalenteach.

Preferred examples of the self-addition diepoxide include those formedfrom a starting material of a liquified bisphenol A diglycidyl ether(i.e., extended with bisphenol A) or an aliphatic-substituted bisphenolA diglycidyl ether. These preferred diglycidyl ether starting materialswill have a molecular weight of from 350 to 2000. Typical preferredcommercial formulations of the diglycidyl ether starting materials aresold under the trade names "EPON 828" and "EPON 1001" (Shell ChemicalCo., Division of Shell Oil Company, 50 West 50th Street, New York,N.Y.), Araldite GY 2600 (Ciba-Geigy, Division of Ciba Corporation, FairLawn, N.J.), or DER 632 (Dow Chemical Co., Midland, Mich.). A preferredexample of the alkylphenol is dodecylphenol.

Examples of amines for the amine mixture include aliphatic diamines andtriamines, aliphatic alcohol amines, alkylene diamines, alkanol aminesand N-alkyl substituted forms thereof. Especially preferred are thealiphatic diamines and alcohol amines having 1 to 10 carbons in thealiphatic group. Especially preferred examples areN,N-dimethylaminopropyl amine, ethanolamine and diethanolamine.

Any blocked polyisocyanate compound may be used as a crosslinker withthe compositions of the present invention. These crosslinkers functionto deblock at temperatures between about 120° C. to about 200° C. Theywill contain at least two, and preferably three or four, crosslinkingsites. A first preferred type is the reaction product of trimethylolpropane, toluene diisocyanate and an alkyl alcohol, which is used as theblocking group. A second preferred type is the reaction product of theisocyanurate of hexane-1,6-diisocyanate and a secondary amine. A thirdpreferred type of cross-linker is a mixture of the two foregoingcross-linkers. A particularly preferred example of the first is theproduct of trimethylol propane, toluene diisocyanate and ethylene glycolmonopropyl ether or ethylene glycol monobutyl ether. A particularlypreferred example of the second reaction product istris(cyanohexyl)isocyanurate and dibutylamine.

These blocked isocyanates are known in the art. The former can beprepared by reaction of the diisocyanate with one equivalent ofbranching moiety followed by one equivalent of the blocking moiety(alcohol or amine) or by the reverse of this addition. The latter can beprepared by reaction of the isocyanurate and blocking amine. The detailsfor their preparation are given in U.S. Pat. Nos. 4,780,524 and4,252,703, the disclosures of which are incorporated herein byreference.

The grind resin according to the invention is an aromatic polyepoxycompound that has been reacted by hydrophilic amine. It is fullydescribed in U.S. application Ser. No. 289,290, filed simultaneouslywith this application and entitled "Pigment Grind Resin", the disclosureof which is incorporated herein by reference. It is the reaction productof one or more aromatic diepoxides with one or more bis-aryl alcohols,an alkylaryl monoepoxide, one or more primary amines and apolyglycolamine. It contains active hydrogen sites (amine and alcoholgroups) that will react with cross-linker. Although its chemicalstructure is not like that of the principal resin, it incorporates intothe three-dimensional matrix of the coating and contributes toprotective properties. A preferred example of the grind resin is thereaction product of bisphenol A diglycidyl ether, bisphenol A,9-amino-3,6-dioxanonan-1-ol, dimethylaminopropylamine andnonyphenolglycidyl ether.

According to the invention, the plasticizer is preferably a nonionicsurfactant material. It functions, in part, to increase the flowabilityand leveling of the coating as it deposits on the metallic substrate. Intheir uncured forms, the combination of crosslinker, principal resin andgrind resin form a very viscous micellular dispersion in aqueous acidicmedium. This viscosity, which tends to inhibit flowability and levelingof the coating being deposited, is substantially decreased by theplasticizing resin. Moreover, the plasticizing resins chosen containhydroxyl groups so that the plasticizing resin will cross-link into thecured network of the final coating.

Examples of the plasticizing resin useful in the present inventioninclude alkylaryloxy polyalkoxy alcohols, such as nonylphenoxypolypropoxy alcohol or cresyloxy polypropoxy alcohol. The latter twoexamples are preferred and are sold commercially under the trade names"Paraplex WP-1" by Rohm & Haas, Inc., Philadelphia, Pa. and "Plastilit3060", BASF AG, Ludwigshafen, Federal Republic of Germany.

A preferred anti-cratering agent according to the invention is apolyacrylate containing pendant alkyl, aromatic, hydroxyalkyl andaminoalkyl groups. It functions to cause uniform adherence of theelectrodeposited coating to the surface of metallic substrate. Itsubstantially minimizes the thinning of coating due to underlyingsurface defects such as the presence of grease, oil or dirt. A preferredexample of the polyacrylate is the free radical addition polymer ofbutyl acrylate, 2-hydroxyethyl acrylate, dimethylaminoethyl methacrylateand styrene.

The pigments include such inorganic ingredients as carbon black,titanium dioxide, zeolite and kaolin clays, lead silicate, magnesiumsilicate, iron oxides, chromium salts, silicon oxides, barium sulfate,organic dyes and catalytic agents such as organotin oxides. They aregenerally described in U.S. Pat. No. 4,780,524.

The pigments are formed into a pigment paste by comminuting them with anaqueous dispersion of grind resin in a known manner (e.g., grind mill,ball mill and the like). Wetting agents, defoamers and surfactants alsocan be added to this grind paste. Typically, grinding to a Hegman grindnumber of no less than 6 will suffice.

The composition according to the invention is prepared in parts. Thefirst part is an emulsion of principal resin, cross-linker, andplasticizing resin, in aqueous acidic medium. The second part is a pasteof grind resin, pigments, defoamer and aqueous medium. The third,optional, part is a mixture of a flow agent of the anti-cratering resinin aqueous medium. These components are combined to form theelectrodeposition bath. In addition to the foregoing ingredients, thebath will also contain defoamers, neutralizing acids, water andsolvents.

The defoamers used in the emulsion paste and bath are commerciallyavailable products containing active hydrogen groups and are useful forpreventing foam-up during preparation of the paste emulsion and theelectrodeposition bath. Typical products useful in this regard arepolyalkoxy nonionic surfactants, high acetylenic diols and other similarnon-silicon containing organic surfactant compounds. Commerciallyavailable defoamers which are preferably useful include TriStar 27(TriStar Chemicals Co., P.O. Box 38627, Dallas, Tex.) and Surfynol 104(Air Products, Allentown, Pa.).

Organic and mild inorganic acids can be used to acidify and disperse theemulsion and paste formulations and the bath. The pH is preferablymaintained at pH 4.5-7. Useful acids include, for example, acetic acid,lactic acid, formic acid and phosphoric acid.

In addition to the primary solvent, water, several other solvents arepresent either as artifacts from the resin synthesis or to facilitatethe solvating power of the aqueous medium. Those solvents include alkylketones, aromatic compounds, alkyl alcohols and glycols and aromaticglycols. Examples include methylisobutyl ketone (MIBK), xylene,isobutanol, n-butanol, propyl glycol, butyl glycol, hexyl glycol andphenyl glycol.

The synthesis of the principal resin follows the procedures laid out inU.S. Pat. Nos. 4,780,524, and 4,661,541, the disclosures of which areincorporated herein by reference. Briefly, the diepoxide startingmaterial is reacted with alkylphenol in a mixture of hydroxylic andlipophilic organic solvents and base catalyst at elevated temperature,preferably 100° C. to 190° C. Approximately 3 to 8, preferably about 3.5to 4.5, equivalents of epoxy group per one equivalent of alkylphenol areused. The phenoxide (from base catalysis) reacts with the diepoxide toform monoepoxy alkoxy ether intermediate which then reacts with anotherdiepoxide molecule to form a dimer. As mentioned above, the reactioncontinues so that dimers, trimers, tetramers, pentamers, and the like,of the diepoxide starting material are ultimately produced. The finaltheoretical molecular weight of the self-addition epoxide resinresulting from this reaction is between 2200 and 3000, while the averagemolecular weight is up to about 7000 to 8000 because of the presence ofthe higher order reaction products. The epoxy functionality of the finalproduct is approximately 1.7 to 2.2.

This intermediate is then further reacted with a mixture of primary andsecondary amines. The amount of amine is chosen so that the ratio ofreactive amine functionality to remaining epoxy functionality on theintermediate is in the range of 0.6 to 1.1, preferably from about 0.75to 1.0.

The synthesis of the cross-linker follows well known techniquesdescribed in the art; see, for example, German Offenlegungsschrift No.2,702,002. Briefly, appropriate molar ratios of blocking alcohol such asethyleneglycol monopropyl ether and toluene diisocyanate are firstreacted and then subsequently is added the appropriate molar amount ofthe branching alcohol, trimethylolpropane. The reverse order of additioncan be employed so that the branching alcohol is added first followed bythe blocking alcohol. Likewise for the synthesis of the isocyanuratecross-linker, the hexane diisocyanate is first catalytically reacted toproduce the isocyanurate and then dibutylamine is added to form theblocked cross-linker.

It has been found according to the invention that when the "branchingalcohol" cross-linker is made by a reverse order addition, the resultingcross-linker deblocks at a lower temperature compared with that of thenormal addition cross-linker. This property in turn provides morecomplete cross-linking in the hardened coating. Yellowing of the coatingand subsequently applied over coats during baking may also be minimizedby the use of this reverse order crosslinker.

The synthesis of the grind resin follows the techniques and procedureslaid out in U.S. Pat. application entitled "Pigment Grind Resin" asreferred to above. The diglycidyl ether of bisphenol A and anotherportion of bisphenol A are adducted under heated conditions in anappropriate solvent such as toluene or xylene. To the resulting chainlengthened diepoxide in a mixture of aromatic and hydroxylic solvents isthen added an equivalent of 9-amino-3,6-dioxanonan-1-ol and anequivalent of dimethylaminopropylamine per two equivalents of diepoxidegroup present. After the amine termination reaction is completed bycontinued heating, about an equivalent of nonylphenol glycidyl ether isadded for reaction with both the unreacted amine still present in thereaction mixture and with the active amine groups present in theintermediate. All reactions are carried out in organic solvent and undereither ambient or elevated temperature.

The synthesis of the anti-crater resin follows a typical polyacrylatepolymerization. The appropriate proportions of acrylate and aromaticolefin monomers are combined with a mixture of ketone and aromaticsolvents. A free radical initiator, such as benzoyl peroxide, persulfideor diazo compound, is added and the reaction stirred under heatedconditions until polymerization is substantially complete. A preferredmethod of performing the polymerization is the addition of the monomersdropwise to the polymerization solution.

Combination of the emulsion, paste, flow agent and solvents to form thecoating bath follows procedures known in the art. Mixture of theingredients following a recipe to produce approximately equivalentamounts of pigment and principal resin and a non-volatile solids contentof approximately 5 to 35 percent will produce an appropriate bath. Ofthe non-volatile solids content, proportions of the various ingredientswill be selected so that the principal resin is about 30 to 55 weightpercent, the pigments are up to about 35 weight percent, thecross-linker is about 15% to 30%, the grind resin is up to about 20%,the plasticizer is about 3% to 12% and the anti-cratering is up to about3%. Preferred weight ranges for these ingredients include about 38% to42% principal resin, about 20% to 25% cross-linker, about 5% to 10%grind resin, about 5% to 8% plasticizer, about 20% to 30% pigment and upto about 1% anti-cratering agent. The preferred pH of the bath is about5.8-6.2.

Pursuant to well-known electrodeposition techniques more fully describedin R. L. Yates, "Electropainting." Robert Draper Ltd., TedelingtonEngland (1966) and German Offenlegungsschrift 2,701,002, the coatingcomposition in the aqueous bath described above can be applied to ametallic substrate. The metal substrate is connected to electrode leadsand immersed in the above-characterized bath contained in a metallictank which serves as the opposite electrode. Deposition is performed ata voltage of up to about 400 volts for periods of up to about 5 minutes,or until a thickness of from about 20 to 28 microns is achieved. Thecoated substrate is then removed from the tank, sprayed with ultrafilterpermeate or deionized water to remove excess bath and then placed in abaking oven. The coating is baked for curing at a temperature of fromabout 120° C. to about 200° C., preferably approximately 150° C. to 180°C. for a period of about 5 to 90 minutes, preferably, 15 to 30 minutes.

Cured coatings produced in this fashion according to the inventiondisplay excellent corrosion resistance, chip resistance, anti-cratering,protective properties as well as exhibiting a smooth, even unblemished,unrippled finish and hiding of substrate blemishes and irregularities.It has been found that the corrosion resistance of this coating has highlevel acceptability when tested in a multiple recycle salt solutionimmersion/humidity scab corrosion procedure. In comparison, commercialstandard-build coatings display a mid level acceptability in this test,while commercial thick-build coatings display high level acceptabilityin this test. Moreover, the compositions of the present invention areless susceptible to thermal degradation during baking cycles, resultingin less air pollution due to low molecular weight thermal degradationproducts.

The cured coating can serve as the protective film for all metallicsubstrates including steel, aluminum, brass, composites, copper, zincplated materials, titanium and the like. It can function as theundercoat paint on autos, trucks, appliances, off-road vehicles, heavymachines, farm machinery and the like.

The invention will be further described in the following examples. Theexamples, however, are not meant as limitations of the invention whichis fully set forth and characterized in the foregoing passages.

EXAMPLE 1 Preparation of Principal Resin A

One-thousand-eight-hundred-five (1805) parts of a liquid epoxy resinbased on bisphenol A with an epoxide equivalent weight of 188 are placedin a reaction vessel provided with a stirrer, reflux condenser, internalthermometer and a nitrogen inlet, together with 450 parts ofnonylphenol, 63 parts of xylene and 7 parts of dimethylbenzylamine. Thereaction mixture is heated to 130° C. and maintained at this temperatureuntil the epoxide equivalent weight reaches a value of 460.Four-hundred-forty (440) parts of xylene are than added and the mixtureis cooled to 80° C. A mixture of 126 parts of diethanolamine and 90parts of N-methylethanolamine is added dropwise. The reaction is allowedto proceed at this temperature for 1 hour, after which 73 parts ofethanolamine are added dropwise, the reaction mixture is maintained fora further 2 hours at this temperature and subsequently diluted with 127parts of hexyl glycol. A clear resin solution with a solids content of80% and MEQ base value of 1.45 milliequivalents/g of solid resin isobtained.

Preparation of Principal Resin B

The procedure for the preparation of the principal Resin A is followed.The epoxide equivalent weight (EEW) approaches 400 in this case. Themodified weights used are as follows:

    ______________________________________                                        Epoxy resin (EEW = 188)                                                                            2,000                                                    tert-Butylphenol     139                                                      Xylene               60                                                       Dimethylbenzylamine  8                                                        Xylene               406                                                      Diethanolamine       280                                                      N,N-dimethylaminopropylamine                                                                       136                                                      Hexyl glycol         166                                                      n-Propanol           413                                                      ______________________________________                                    

A clear resin solution with a solids content of 74.8% (measured for 1hour at 190° C.) and a MEQ base value of 2.15 milliequivalents/g ofsolid resin is obtained.

Preparation of Principal Resin C

In a similar manner to the preparation of the principal Resin A, 1805parts of an epoxy resin (EEW =188), 352 parts of nonylphenol, 67 partsof xylene and 10 parts of dimethyllaurylamine are allowed to react to130° C. until an epoxide equivalent weight of 450 is reached. A 71.3%solution of ethanolamine/methyl isobutyl ketimine in methyl isobutylketone is added dropwise in the course of 1 hour at this temperature.The reaction is allowed to proceed for a further 7 hours, and themixture is then diluted to a solids content of 83.5% (1 hour at 130° C.)with 141 parts of hexyl glycol. The resin has a MEQ base value of 1.68milliequivalents/g of solid resin.

Preparation of a Cross-linking Agent I

A blocked isocyanate cross-linking agent (polyurethane cross-linkingagent, reverse order) is prepared according to the following procedure.Slowly and with stirring in a nitrogen atmosphere is added 291 parts ofan 80/20 isomeric mixture of 2,4-/2,6-toluene diisocyanate 0.08 parts ofdibutyltin dilaurate and 180 parts of methyl isobutyl ketone, thetemperature being maintained below 38° C. The mixture is maintained at38° C. for a further half hour after which 75 parts oftrimethylolpropane are added. After allowing the reaction to proceed forabout 10 hours, 175 parts of ethylene glycol monopropyl ether is addedand the mixture reaction kept 1.5 hours at 121° C. until essentially allthe isocyanate groups are reacted. This depletion is recognized from theinfrared spectrum.

The normal order blocked isocyanate can be prepared by the altering theforegoing order of addition pursuant to Example 1 of GermanOffenlegungsschrift 2,701,002.

Preparation of Cross-linking Agent II

A blocked isocyanate crosslinker (polyurea) is prepared according to thefollowing procedure. Four-hundred-eighty-three parts of triisocyanuratedhexamethylendiisocyanate and 193 parts of 2-hexanone are charged to adry reactor. Dibutylamine (307 parts) are added slowly and with stirringunder nitrogen atmosphere so that the temperature does not exceed 80° C.After all amine has reacted 14 parts of n-butanol and 0.2 parts ofdibutyl tin dilaurate are added. The reaction mixture is heated to 80°C. until no isocyanate groups can be detected by infrared analysis.

Preparation of Aqueous Emulsions I-IV

The principal resins are then converted to aqueous emulsions by mixingthe components listed in the table below and adding deionized water(emulsion 1). After 20 minutes homogenization, the mixture is furtherdiluted, batchwise, with deionized water (emulsion 2). The dispersionsare subsequently subjected to a brief vacuum distillation, the organicphase being separated off from the distillate.

    ______________________________________                                        Emulsions    I         II      III     IV                                     ______________________________________                                        Principal Resin A                                                                          937.0     937.0   --      --                                     Principal Resin B                                                                          --        --      1002.0  --                                     Principal Resin C                                                                          --        --      --      898.0                                  Cross-linking Agent I                                                                      630.0     528.0   --      528.0                                  Cross-linking Agent II                                                                     --        --      388.0   --                                     Dibutyltin Dilaurate                                                                       --        8.0     --      8.0                                    Solution of Lead (II)                                                                      28.0      --      28.0    --                                     octoate (24% Pb)                                                              Antifoam Solution                                                                          1.2       1.2     1.2     1.2                                    Glacial Acetic Acid                                                                        26.1      26.1    29.1    33.7                                   Deionized Water 1                                                                          748.0     748.0   820.0   780.0                                  Deionized Water 2                                                                          1493.0    960.0   2240.0  1760.0                                 Solids (1 hr. at                                                                           31.8%     35.1%   26.4%   28.5%                                  130° C.)                                                               ______________________________________                                    

EXAMPLE 2 Preparation of Principal Resin D

The epoxy resin (liquid epoxy resin based in bisphenol A with an epoxideequivalent weight (EEW) of 188, see Table I for list of weights) isinitially taken in a suitable reactor together with the phenol (seeTable 1) and heated to 160° C. under a nitrogen blanket. Thistemperature is maintained until EEW I is reached. The mixture is thencooled by the addition of methyl isobutyl ketone (MIBK) and by externalcooling to 125° C., and benzyldimethylamine is added. The temperatureagain slightly increases and it is maintained at 130° C. until EEW II isreached. The ketimine (prepared from diethylenetriamine and an excess ofMIBK, so that an amine equivalent weight of 125 results) anddiethanolamine are added. The temperature is maintained for 1 hour at110° C., propylene glycol monophenyl ether is then added and the mixtureis stirred for 30 minutes. The cross-linking agent I or II prepared asdescribed in Example 1 is then added and the mixture is cooled to 90° C.

In the meantime, the dispersing bath is prepared from deionized water(H₂ O I) and glacial acetic acid. The solution of the resin is dispersedtherein. After 30 minutes lead octoate is added and stirring iscontinued for a further 30 minutes. A further quantity of water is thenadded (H₂ O II) and stirring continued for 15 minutes. The dispersion isthen filtered.

                  TABLE I                                                         ______________________________________                                        Quantities Weighed Out for Principal Resin Preparation                                          Binder I                                                                              Binder II                                           ______________________________________                                        Epoxy resins        1162      1310                                            Phenol              t-Butyl-  p-Dodecyl-                                                          phenol    phenol                                          MIBK                75        110                                             Benzyldimethylamine 8         7                                               Cross-linking agent Type I    Type II                                         Diethanolamine      120       109                                             Ketimine            144       94                                              Propylene glycol monophenyl                                                                       123       159                                             ether                                                                         H.sub.2 O I         1370      1690                                            Glacial acetic acid 49        50                                              Lead octoate        24        146                                             H.sub.2 O II        2515      2100                                            EEW I               385       370                                             EEW II              950       1080                                            Solids (2 hours, 110° C.)                                                                  34.8%     35.7%                                           ______________________________________                                    

EXAMPLE 3 Preparation of Principal Resin E

To a clean dry reactor is added xylene. The mixing liquid is blanketedwith pure N₂ and heated to 42° C.

Solid epoxy (characteristics and weights in Table II) is added at such arate that the batch temperature never drops below 60° C., usually over aperiod of two hours. Heating is continued until 100° C. At this point,the dodecyl phenol is added and then heated to 118° C. Vacuum drying bydistillation of xylene is started at this temperature and continuedheating to 125° C. The pressure should be between 66 cm and 69 cm of Hg(88 kP-92 kP) at full vacuum. The drying stage should take between 1.0and 1.5 hours. Break vacuum with pure nitrogen only. The batch is cooledto 115° C. The sample at this point should be (%non-volatiles (% N.V.)=95.0±0.5).

At 115° C. benzyldimethylamine (BDMA) is added. The peak exothermtemperature should reach 129°-132° C. The temperature is maintained at130° C.±2° C. and the polymerization is followed by EEW titration. Every30 minutes the reaction is sampled and is stopped at an end point of1100±10 EEW. The typical reaction time is 3 hours. Adjustments to thecatalyst level may be necessary if extension period is ±30 minutes from3 hours

At the target EEW, the reducing solvents are added followed by diethanolamine (DEOA).

The temperature of this reaction should not exceed 132° C. Cooling maybe necessary at this point with jacket or coils. A vacuum suction isstarted immediately after the DEOA addition and pressure is reduced to18 inches of Hg and held for 5 minutes. The pressure is further reducedin 2 inch Hg increments followed by short holding period until 26-27inches of Hg is achieved. The batch is then cooled to 90° C. in one hourfollowing addition of DEOA. To achieve this a good reflux rate should beattained in 20-25 minutes after the DEOA addition. All solvents arereturned to the reactor.

After one hour of vacuum cooling, (T=90° C.), ethylene glycol monohexylether and isobutanol are added without breaking vacuum. The batch iscooled for 35 minutes to 59° C.±2° C. under full vacuum to achieve thetarget temperatures during the specified time tables.

The dimethylamino propyl amine (DMAPA) is charged as fast as possibleafter the 35 minute cooling period. The batch temperature is kept below63° C. The batch is held is kept between 54° C. and 60° C. for two hoursafter exotherm. Then it is heated 90° C. over one hour and thistemperature is held for one hour. The batch is cooled to 80° C.

                  TABLE II                                                        ______________________________________                                        Characteristics and Weights of Ingredients                                    Weight       Ingredient                                                       ______________________________________                                        81.1         Xylene                                                           33.9         Xylene                                                           568.1        EPON 1101F (EEW = 530 ± 10)                                   75.9         Dodecyl phenol                                                   1.1          BDMA                                                             42.1         Ethylene glycol                                                               monobutyl ether                                                  74.7         Xylene                                                           42.6         DEOA                                                             40.6         Ethylene glycol                                                               monohexyl ether                                                  107.7        Isobutanol                                                       13.3         DMAPA                                                            1000.0       Total Weight Principal                                                        Resin 70% N.V.                                                   ______________________________________                                    

Preparation of Emulsion

With the foregoing principal resin stirring at 80° C. (see Table III forweights) the acetic acid and plasticizer, Paraplex WP-I (sold by Rohm &Haas, see Table III) are added, followed by addition of crosslinker Iprepared as described in Example 1. The resin mixture at this pointshould be at about 56° C. It is mixed for 15 minutes. The acetic acid isadded to the batch and it is mixed thoroughly for one hour. Batchtemperature should not exceed 57° C.

Then, over a period of 1 to 1.5 hours, the resin premix and acid asformulated above is added with agitation to the H₂ O and Surfynol 104(50% in ethylene glycol monobutyl ether starting at 25° C. This step isthe high viscosity shear stage. Good mixing is important here,(N.V.=55%). The temperature at this point should be 37° C. to 40° C. Themix is stirred for the next portion of H₂ O over a period of 2 hours(about) 0.2 gal/min). It is held and mixed 30 minutes. The temperatureshould be between 30° C. and 32° C. If good mixing is not observed, addremaining H₂ O at the same rate as above. The remaining water is added.Final emulsion temperature should be 27° C.-30° C.

                  TABLE III                                                       ______________________________________                                        Emulsion                                                                      Weight       Ingredient                                                       ______________________________________                                        302.0        Principal Resin                                                               70% N.V.                                                         28.3         Plasticizer-Nonylphenoxy                                                      Polypropoxyethanol (100% N.V.)                                   162.6        Crosslinker I (70.0% N.V.)                                       4.84         Acetic Acid                                                      142.8        H.sub.2 O Portion I                                              0.68         Ethylene glycol                                                               monobutyl ether                                                  200.0        H.sub.2 O Portion II                                             103.6        H.sub.2 O Portion III                                            ______________________________________                                    

EXAMPLE 4 Preparation of Grind Resin

This general procedure was used to prepare a grind resin according tothe present invention. First, 27.81 parts of the diglycidyl ether ofbisphenol A and 1.44 parts xylene were charged into a reaction vessel.The charge was heated to 82° C. under a dry nitrogen atmosphere. Next,the heating of the reaction vessel was discontinued and a charge of 5.81parts bisphenol A was added, together with 0.002 parts triphenylphosphine catalyst. The heating of the reaction vessel was thencontinued to a temperature of 127° C. At this time, the reactionexothermed on its own, with a peak of about 150° C.-160° C. Theextension was held above 150° C. until a EEW of 350±10 achieved (about345).

Once the above-mentioned EEW was reached, 21.08 parts ethylene glycolmonobutyl ether was added to the reaction vessel and the bath was thencooled to 49° C.

After a temperature of 49° C. is achieved, and a mixture of 7.77 partsof 9-amino-3,6-dioxanonan-1-ol and 4.07 parts dimethylaminopropylaminewere added to the reaction vessel over a period of 6 minutes, followedby a pump flush of 0.53 parts ethylene glycol monobutyl ether. The batchexothermed to 104° C.-110° C., and the exotherm was held at or below115° C. for one hour. Next, 4.92 parts ethylene glycol monobutyl etherwas charged into the reaction vessel and the batch was cooled to 77° C.Next, 14.9 parts nonylphenolglycidyl ether was charged into the reactionvessel followed by a pump flush of 1.53 parts of ethylene glycolmonobutyl ether. The batch exothermed to 88° C.-93° C., and the batchwas held at this temperature for one hour. Finally, 10.03 parts ethyleneglycol monobutyl ether was charged into the reaction vessel and thebatch was cooled to 66° C. The resultant product was then filtered offthrough 25 micron bags and drummed.

The non-volatile content of the grind resin prepared in Example 1 wasdetermined to be 60.0%, the weight per gallon 8.53 and the viscosity wasabout 4900 centipoises at 25° C.

Preparation of a Gray Pigment Paste

Eighteen-hundred (1800) parts of the grind resin prepared according tothe foregoing procedure of this Example was initially taken with 2,447parts of deionized water, followed by 2,460 parts of TiO₂, 590 parts ofan extender based on aluminum silicate, 135 parts of lead silicate and37 parts of carbon black. This mixture is comminuted by grinding to aHegman number of from 5 to 7. One-thousand-two-hundred-fifty-five(1,255) parts of deionized water are added in order to obtain thedesired paste consistency. This gray paste has a very long shelf life.

EXAMPLE 5 Preparation of Electrocoating Baths I and II and Deposition ofCoating Films

Two-thousand (2000) parts by weight of each of the principal resinemulsions described in Example 2 are mixed with 775 parts by weight ofthe above-described gray pigment paste. The bath solids are adjusted to20% with deionized water (150° C., 30 minutes). The bath is then allowedto age for 3 days with stirring. The deposition of the coating films onzinc phosphated panel takes place during 2 minutes. The bath temperatureis 27° C. The deposited films are baked at 180° C. for 20 minutes.

EXAMPLE 6 Preparation of Electrocoating Bath With Principal Resin E andDeposition of Coating Film

Approximately 1900 parts of the emulsion of Example 3 (32% N.V., 600N.V. parts), about 525 parts of the pigment paste prepared according toExample 4 but containing the ingredients and amounts given in Table IV,about 23 parts of an acrylic flow solution prepared as given below inTable V, about 1600 parts water, about 20 parts Dowanol PPH (DowChemical Company) and about 1 part 25% acetic acid are combined atambient temperature and mixed for about one hour. The bath solids areadjusted with aqueous acid, if necessary, to yield a solids content ofabout 21 to 24 percent.

The bath is placed in a pilot electrodeposition tank and allowed to agefor 3 days with circulation. Electrodeposition of zinc phosphated panelsis then performed by emersion of the panels in the bath for about 2minutes at a voltage of 340 V and a temperature of 27° C. The coatedpanels are rinsed, then baked at 180° C. for 20-30 minutes to harden thefilms.

    ______________________________________                                        Results of Deposition                                                         ______________________________________                                        Film thickness      24 microns                                                GM throwing power (cm)                                                                            31.8 cm                                                   Scab corrosion test 3 mm Scribe creep                                         Gm Gravelometer test                                                                              Pass                                                      Water spot resistance                                                                             Excellent                                                 ______________________________________                                    

                  TABLE IV                                                        ______________________________________                                        Paste Formula                                                                           Total   NV           Bind  %     %                                  Component Wt      Wt     Pig Wt                                                                              Wt    PS    Total                              ______________________________________                                        Grind resin of                                                                          198.3   119.0  --    119.0 --    19.83                              of Example 4                                                                  Acetic Acid                                                                             11.1    --     --    --    --    1.11                               Defoamer  7.0     --     --    --    --    0.70                               (Tristar 27)                                                                  Carbon Black                                                                            12.6    12.6   12.6  --    3.0   1.26                               1.26                                                                          Lead Silicate                                                                           14.7    14.7   14.7  --    3.5   1.47                               (Basic White                                                                  Lead)                                                                         Clay Extender                                                                           63.0    63.0   63.0  --    15.0  6.30                               Titanium  329.7   329.7  329.7 --    78.5  32.97                              Dioxide                                                                       Dibutylin Oxide                                                                         21.0    21.0   --    21.0  --    2.10                               (Fine Ground)                                                                 DI Water  342.6    --    --     --   --    34.26                              Totals    1000.0  560.0  420.0 140.0 (100.0)                                                                             (100.0)                            ______________________________________                                         Formulated For: 56.0% N.V. Before Reduction Grind Resin Parameters 60.0%      N.V.; 489 AEW Neutralization 75.0%                                       

                  TABLE V                                                         ______________________________________                                        Flow Agent Solution                                                           Component         Total Wt. NV Wt.                                            ______________________________________                                        Acrylic Flow Resin*                                                                             285.7     229.1                                             25%                                                                           Acetic Acid       54.9      --                                                DI Water          659.4     --                                                Totals            1000.0    229.1                                             ______________________________________                                         *Prepared by free radical polymerization of 20 wt. % butyl acrylate, 58       wt. % 2hydroxyethyl acrylate, 20 wt. % dimethylaminoethyl methacrylate an     2 wt. % styrene.                                                         

We claim:
 1. A coating composition comprising:a principal resincomprising a self-addition epoxide resin-polyamine adduct with pendantalkylphenoxy groups; a cross-linker comprising a blocked polyisocyanatecompound; a grind resin comprising the reaction product of an aromaticdiepoxide, a bis (aromatic alcohol), a polyglycolamine, a diamine and analkaryl monoepoxide; a plasticizer; and pigments selected from a groupconsisting of inorganic, organometallic and organic compounds.
 2. Acomposition according to claim 1, further comprising a defoamer,neutralizing acids and solvents.
 3. A composition according to claim 1,further comprising an anti-cratering agent selected from polyacrylateresins, polyether resins, polyester resins, and silicone resins
 4. Acomposition according to claim 3 wherein said anti-cratering agent is apolyacrylate resin having alkyl, aromatic, and dialkylamino pendantgroups.
 5. A composition according to claim 1 wherein said crosslinkeris a toluene diisocyanate compound, a blocked isocyanurate of a hexanediisocyanate compound or mixtures thereof.
 6. A composition according toclaim 1 wherein said plasticizer is a poly(alkylene oxide) alcoholcompound.
 7. A composition according to claim 1, wherein the principalresin is the reaction product of a self-addition epoxide resin and amixture of amines selected from the group consisting of amino alcoholsand alkyldiamines, the equivalent ratio of amine mixture to adduct beingfrom about 0.75 to 1 amine equivalent per epoxide group;theself-addition epoxide resin being the reaction product of an aromatic oralkylaromatic diepoxide having a molecular weight of from about 350 to1500 and a phenol of the formula RC₆ H₄ OH wherein R is hydrogen or analkyl group of from 1 to 18 carbons, and the equivalent ratio ofdiepoxide to alkyl phenol being about 3 to 8 epoxy groups per phenolgroup.
 8. A composition according to claim 7 wherein the equivalentratio of diepoxide to alkylphenol is 3.5 to 4.5 epoxy groups per phenolgroup.
 9. A composition according to claim 8, wherein the diepoxide isformed by reacting bisphenol A and a diglycidyl ether wherein thediglycidyl ether has a molecular weight of from about 300 to about 800.10. A composition according to claim 7, wherein the adduct is formedfrom bisphenol A, glycidyl chloride and alkyl glycidyl ether of fromabout 4 to 12 carbons.
 11. A composition according to claim 1, whereinthe cross-linker is the reaction product of trimethylolpropane, toluenediisocyanate and an alkyl alcohol of from 4 to 12 carbons.
 12. Acomposition according to claim 1, wherein the cross-linker is thereaction product of the isocyanurate of hexane-1,6-diisocyanate and asecondary amine.
 13. A composition according to claim 12, wherein thesecondary amine has from 3 to 6 carbons in each alkyl group.
 14. Acomposition according to claim 1, wherein the grind resin is a reactionproduct of bisphenol A diglycidyl ether, bisphenol A, nonylphenylglycidyl ether, N,N-dimethyl propylene diamine and9-amino-3,6-dioxanonan-1-ol.
 15. A composition according to claim 1,wherein the plasticizer is nonylphenoxypolypropoxy alcohol orcresyloxypolypropoxy alcohol.
 16. A composition according to claim 1,wherein the anti-cratering agent is a polymer of C₁ -C₆ alkyl acrylate,styrene, C₁ -C₆ hydroxyalkyl acrylate and dimethylaminoethyl acrylate.17. A composition according to claim 1, wherein the weight percentranges of ingredients relative to total weight of nonvolatile solids areabout 30% to 55% of principal resin, about 15% to 30% of cross-linker,up to about 20% of grind resin, about 3% to 12% plasticizer, up to 35%pigments and up to about 3% anti-cratering agent.
 18. A compositionaccording to claim 17, wherein the weight percentages are about 40%principal resin, about 22% cross-linker, about 7% grind resin, about5.5% plasticizer, about 25% pigments, and about 0.5% anti-crateringagent.
 19. A coating composition comprising: about 30% to 55% of aprincipal resin formed by adducting a mixture of an amino alcohol of 4to 8 carbons and primary/tertiary diamine with the self-condensate of analkyl phenol of the formula RC₆ H₄ OH, R being hydrogen or an alkyl of 1to 18 carbons, and bisphenol A-liquified-bisphenol A diglycidyl etherhaving a molecular weight of about 350 to 1500;about 15% to 30% of ablocked isocyanate cross-linker formed from trimethylol propane, toluenediisocyante and alkyl alcohol of 4 to 12 carbons, or from theisocyanurate of hexane-1,6-diisocyanate and secondary amine having from3 to 6 carbons in each alkyl group, or a mixture thereof; up to about20% of a grind resin formed from bisphenol A diglycidyl ether, anaromatic diol, 9-amino-3,6-dioxanonan-1-ol, N,N-dialkyl alkylenediamineof 4 to 12 carbons and nonylphenolmonoglycidyl ether; about 3% to 12% ofa plasticizer comprising nonylphenoxypolypropoxy alcohol orcresyloxypolypropoxy alcohol; and up to about 35% pigments comprisinginorganic, organometallic, or organic compounds or mixtures thereof; thepercentage being in weight relative to the total weight of thecomposition.
 20. A composition according to claim 19 further comprisingup to about 3% of an anti-cratering agent comprising a polymer of alkylacrylate, styrene, hydroxyalkyl acrylate and dimethylaminoethylacrylate.
 21. A coating composition comprising:about 40% of a principalresin formed by adducting a mixture of diethanolamine andN,N-dimethylpropylene diamine with the self-condensate of nonylphenoland the diepoxide bisphenol A-liquified-bisphenol A diglycidyl etherhaving a molecular weight of 350 to 1500; about 22% of a blockedisocyanate cross-linker formed from trimethylolpropane, toluenediisocyanate and 3-oxahexan-1-ol; about 7% of a grind resin formed frombisphenol A diglycidyl ether, bisphenol A, nonylphenylmonoglycidylether, 9-amino-3,6-dioxanonan-1-ol and N,N-dimethylpropylene diamine;about 5.5% of a plasticizer selected from nonylphenoxypolypropoxyethanoland cresylphenoxypolypropoxyethanol; about 0.5% of an anti-crateringagent comprising a polymer of butyl acrylate, 2-hydroxyethyl acrylate,dimethylaminoethyl acrylate and styrene; and about 25% pigmentscomprising inorganic, organic compounds mixtures thereof.
 22. A coatingcomposition according to claim 19, 20 or 21 wherein the equivalent ratioof amine mixture to self-addition epoxy resin is from about 0.75 toabout 1 amine equivalent per epoxide group.
 23. A coating compositionaccording to claim 19, 20 or 21 wherein the equivalent ratio ofdiepoxide to alkylphenol is 3:1 to 8:1 epoxy to phenoxy groups.
 24. Acoating composition according to claims 19, 20 or 21 wherein theequivalent ratio of diepoxide to alkylphenol is 3.5:1 to 4.5:1 epoxy tophenoxy groups.
 25. A coating bath comprising a mixture of about 20 to30 weight percent of the composition of any one of claims 1 through 21,and a remaining weight percent of defoaming agents and an acidic,aqueous medium of pH about 4.5 to
 7. 26. An article electrocoated with acomposition according to any one of the claims 1 through 21.